hw-checkout-guide

MBARI DIC Controller Hardware Checkout Guide

Materials
Board Preparation
Firmware Installation
Test Procedures
Pre-test
Console and Host Port
Licor Serial Port
Set Real Time Clock
Analog Inputs
Battery Voltage Input
Valve Ports
Pump Ports
SD Card

Materials

PCB
fuses (BK/PCS 1-5A slow blow)
RTC backup battery (CR1620 or equivalent)
SD card (16GB micro SDHC UHS-1 or better)
console cable
host cable
DMM or oscilloscope
1x 3-pin ADC/SV test cable
1x 2-pin Pump test cable
10-20k pot
2x MM jumper wire(s)
2x MF jumper wire(s)
test clips
F-F DB9 serial loop back connector or Phoenix w/ comms looped back
12V 2A power supply
Microchip ICD4 programmer w/ RJ45 programming cable
MPLAB host computer (OSX/Win/Linux)
MPLABX IDE v5.40
XC16 v1.50
Code Configurator Plugin 3.95.0
IDE Platform Plugin 1.29
device pack PIC24F-GA-GB_DFP 1.1.74
PIC24/dsPIC33/PIC32MM MCU peripheral library 1.167.0
16-bit bootloader v1.17.2

Optional * Java (for Unified Host app if installing serial bootloader)

Resources

Board Preparation

install the RTC backup battery

BT1 on left end of PCB
'+' side up
The solder pads lift easily, don't lift retainer clip.

install the fuses

sockets F1, F2 on PCB 
upper right, near console and host cables

connect cables
- the ICD4 programming cable to the PCB
- connect the ICD4 USB cable to the MPLAB host computer
- connect the console cable power leads to the power supply
get the firmware repo (either option)
- clone firmware git repo

       git clone git@bitbucket.org:mbari/carbonwg-pic.git

checkout the binlog branch

 $ cd carbonwg-pic
 $ git checkout feature/binlog

install system files on the SD card
- use an SD Card reader to mount the SD card
- copy the system files from carbonwg-pic/sdc to the SD card
```
 SYSBOOT.SCR  
 CONFIG.TXT  
 HELP.MD  
 DIC2.SCR  
```
edit CONFIG.TXT (on the SD card) and set the serial number field
if using OSX or linux, run unix2dos on the files to make sure have correct line endings

 $ dos2unix path/to/sdcard/*

install the SD Card in the PCB socket

Firmware Installation

There are two firmware options

stand-alone
- simpler to install
- firmware updates require ICSP programmer, e.g. ICD4
with serial bootloader
- firmware updates may be done via console port
- requires Microchip Unified Host Java app (distributed with firmware repo)

procedure: Install stand-alone

open the pic firmware project

 File > Open Project... > carbonwg-pic/cwg-pic.X

select the cwg_nonboot configuration

[carbonwg project non-boot configuration]

clean/build
make and program device

procedure: Install serial bootloader version

Installing the serial bootloader version is a three step process:

build and install the bootloader firmware
build the carbonwg firmware (uses a different configuration than stand-alone)
use the bootloader together with the Microchip Unified Host app to load the carbonwg firmware

Step 1: build and install the bootloader firmware

open the bootloader firmware project

 File > Open Project... > carbonwg-pic/cwg-bl.X

clean/build
make and program device

Step 2: build and install the carbonwg firmware (bootloadable configuration)

open the bootloader firmware project

 File > Open Project... > carbonwg-pic/cwg-pic.X

select the cwg_boot configuration
clean/build
WAIT (do not make and program device)

Step 3: Use the bootloader and Unified Host app to load the carbonwg firmware

unzip the Unified host file carbonwg-pic/utils/unifiedhost--bin.zip creates directory UnifiedHost-
double click the jar file to run the app UnifiedHost-/UnifiedHost-.jar
configure the Device Architecture PIC24/dsPIC33/PIC32MM MCUs
configure the Unfied Host serial port (i.e. controller console port, not host port) Settings > Serial… Bits per second 38400 Data bits 8 Stop bits 1 Parity Disabled

configure the firmware image address range Application Start (Byte Address):0x1800 Application End (Byte Address):0x5B000

select the cwg_boot firmware image File > Open/Load (*.hex) > cwg-pic.X > dist > cwg_boot > production > cwg-pic.X.production.hex

optionally, uncheck Enable Read Back Verification After Program (slower, but recommended to verify)
leave the Unified Host app window open
use a terminal emulator (e.g. hyperterm, minicom, etc.) to open a console session to the controller console port - the same one used by the Unified Host. Configure using 38400N81.
cycle power to the board
- On power up, the LED will stay lit for 2 seconds.
- When it turns off, type UUUU within 10 seconds to activate the bootloader
- Each character typed should be echoed, the LED should flash when it receives a ‘U’
- The LED will stay lit when the bootloader is active (10s max or when UUUU sequence complete)
- The LED will flash 3 times then turn off if the bootloader is NOT activated (cycle power and start again)
close the terminal emulator, and return to the Unified Host session window
click the “Program Device” button to begin programming the device. The process takes ~5-10 min.
when the programming cycle is complete, the board should reset.
- The LED will light for 2 S
- After ~10s, the LED will flash three times and boot the firmware
- The LED will flash at 1 Hz for a few seconds and stop flashing if no console input is received
Now it should be possible to initiate a terminal session on the console port (9600N81)

Test Procedures

Pre-test

complete board prep checklist (above)
turn off power to the controller board
unplug all cables
testing should be conducted on a non-conductive, static safe surface

Console and Host Port

install console port cable
open a terminal session (9600N81)
issue a reset command

 >> reset

 serial IO [OK]
 sdc mount [OK]
 log_init  [OK]
 Loading config...cfg load  [OK]
 running boot script...
 00:00:03
 bootstrap [OK]

 CarbonWG build [Aug 12 2020, 14:20:08]
 SN: 0002
 status[x0044/0000]

repeat for host port, host cable
PASS:
- executes reset
- both cables/ports work

Licor Serial Port

install instrument port cable
install loopback connector (or connect DB-9 pins 2,3)
perform loopback test

 >> con licor

[typed characters - should be echoed] * remove loopback connector
[typed characters - should not be echoed] * measure licor port power (pins 1,4 - ~11-12 V)

enter CTRL-D to quit con session
measure licor port power (pins 1,4 - ~0 V)
PASS:
- port power responds, voltage levels correct
- serial port loopback test OK

Set Real Time Clock

establish a console session
set the time (YYYY M D H M S)

 >> set time 2019 11 20 14 20 0

get the time (should be later than set time)

 >> get time 
 2019-11-20T14:27:20Z

issue reset or cycle power
get the time (should be later than previous check)

 >> get time
 2019-11-20T14:32:20Z

PASS:
- time retained across power cycle
- time matches value entered

Analog Inputs

connect 10-20k pot center/end to pins 2,3 of ANALOG port
assert ADC enable bits

 >> set bits a*

read ADC for ends and middle of pot range

 >> GET AD 0 1
 ADC0 :  3.5547 V
 ADC1 :  4.9805 V

repeat for channels 0,1
PASS:
- voltage should vary X-5V (0<X<5, depending on pot value)

Battery Voltage Input

read ADC2 (VBATT)

 >> GET AD 2
 ADC0 :  11.4001 V

PASS:
- voltage should be ~11-12V

Valve Ports

install 3-pin test cable on port SV0
connect a DMM or scope to the test cable
- DMM negative:
- DMM positive: SVn:A
assert all SV ports ON

 >> set bits v* pa ps
 >> get bits

DMM should indicate ~11-12V
Move the connector to each of the SV*A ports (check voltage)
Connect the DMM to the B port and repeat for SV*B
assert all valve ports OFF

 >> clr bits v* pa ps
 >> get bits

repeat SVA, SVB checks (should be ~0.3V)
PASS:
- all valve ports should on/off @ nominal voltage

Pump Ports

install 2-pin test cable on port P0
connect a DMM or scope to the test cable
- DMM negative: P0-
- DMM positive: P0+
assert all Pump ports ON

 >> set bits p*
 >> get bits

DMM should indicate ~11-12V
Move the connector to each of the pump ports (check voltage)
assert all valve ports OFF

 >> clr bits p*
 >> get bits

repeat P( checks (should be ~0.0V)
PASS:
- all pump ports should cycle on/off @ nominal voltage

SD Card

run filesystem info utility

 >>dstat
 FAT type                    FAT32
 Bytes/Cluster               32768
 Number of FATs                  2
 Root DIR entries                0
 Sectors/FAT                  3834
 Number of clusters         490720
 Volume start (lba)           8192
 FAT start (lba)              8716
 DIR start (lba,clustor)         2
 Data start (lba)            16384
 
 768312 bytes in 71 files 16 directories
 15703040 KiB total   15700192 KiB available